Systems and methods for drill bit and cutter optimization

Abstract

A drill bit analysis and optimization system for use in a wellbore is provided. The system includes a drill bit including a cutter, a sensor that collects a data signal on a surface of the drill bit proximate to the cutter, and a signal processor unit that receives the data signal from the sensor and receives the expected drilling properties from the data reservoir. The processor analyzes the data signal to detect a resistivity profile from the sensor through a formation and optimizes a drilling parameter by comparing actual drilling properties with expected drilling properties.

We claim: 
     
       1. A drill bit analysis system for use in a wellbore comprising:
 a drill bit having a plurality of cutters on an exterior surface thereof; 
 a sensor disposed on the surface of the drill bit proximate to a cutter from the plurality of cutters, wherein the sensor generates a data signal; and 
 a signal processor unit that: 
 receives the data signal from the sensor; 
 analyzes the data signal to derive actual drilling properties of a subterranean earthen formation that is encountered by the cutter; 
 calculates a distance between the sensor and the subterranean earthen formation from at least one of the data signal, a resistivity profile, and a stored drilling algorithm; 
 compares the actual drilling properties with expected drilling properties; 
 determines at least one of an adjustment to a drilling parameter and a change in an operation of the drill bit based on a comparison of the actual drilling properties with the expected drilling properties; and 
 performs at least one of the adjustment to the drilling parameter and the change in the operation of the drill bit. 
 
     
     
       2. The system of  claim 1 , wherein the signal processor unit derives the actual drilling properties of the subterranean earthen formation from one or more of the data signal, the resistivity profile, and the distance. 
     
     
       3. The system of  claim 1 , further comprising:
 a second sensor disposed on the exterior surface of the drill bit on an opposite side of the cutter, wherein the signal processor unit further derives the actual drilling properties of the subterranean earthen formation from a second signal generated by the second sensor. 
 
     
     
       4. The system of  claim 3 , wherein the sensor is located ahead of the cutter in a direction of bit rotation and the second sensor is located behind the cutter in a direction of bit rotation, and wherein the signal processor unit uses differences between the data signal and the second signal to determine the adjustment to the drilling parameter. 
     
     
       5. The system of  claim 4 , and further comprising a third sensor and a fourth sensor, wherein the third and fourth sensors are disposed on the exterior surface of the drill bit proximate to the cutter along an axis that is perpendicular to the direction of bit rotation, and wherein the signal processor unit generates a contour map of the subterranean earthen formation showing a cut surrounding the cutter. 
     
     
       6. The system of  claim 1 , wherein wherein the signal processor unit adjusts the drilling parameter of the drill bit during drilling operations. 
     
     
       7. The system of  claim 1 , wherein a drilling property of the drilling properties is a condition of the cutter, and wherein the signal processor unit determines when such cutter should be replaced in response to determining the condition. 
     
     
       8. The system of  claim 1 , wherein a drilling property of the drilling properties is a condition of the subterranean earthen formation, and wherein the signal processor unit performs the adjustment to the operation of the drill bit in response to a change in the condition of the subterranean earthen formation. 
     
     
       9. A drill bit cutter sensor system for use in a wellbore comprising:
 a first sensor disposed on a surface of a drill bit proximate and in front of a cutting edge of a cutter, wherein the first sensor receives a first data signal; 
 a second sensor disposed on the surface of the drill bit proximate and behind the cutter, wherein the second sensor receives a second data signal; and 
 a signal processor unit operable to: 
 measure a first resistivity profile and a second resistivity profile using the first data signal and the second data signal, respectively, 
 determine a first distance between the first sensor and a subterranean earthen formation and a second distance between the second sensor and the subterranean earthen formation using an inversion scheme, 
 derive actual drilling properties using the first resistivity profile, the second resistivity profile, the first distance, and the second distance, 
 compare the actual drilling properties and expected drilling properties; and 
 change an operating parameter of the drill bit during drilling operations based on a comparison of the actual drilling properties with the expected drilling properties. 
 
     
     
       10. The system of  claim 9 , wherein the signal processor unit recommends a repair or replacement of the cutter. 
     
     
       11. A method of drill bit analysis using a sensor in a drill bit in a wellbore, the method comprising:
 collecting a data signal using the sensor disposed proximate to a cutter on the drill bit; 
 measuring, using a processor and the collected data signal, a resistivity profile from the sensor through a formation; 
 calculating, using the processor, a distance between the sensor and the formation; 
 deriving actual drilling properties of the wellbore from the resistivity profile and the distance; 
 comparing between the actual drilling properties and expected drilling properties; 
 determining a drilling parameter based on the comparison between the actual drilling properties and the expected drilling properties; and 
 performing an adjustment of the drilling parameter. 
 
     
     
       12. The method of  claim 11 ,
 wherein the drilling parameter is a real-time drilling parameter, 
 wherein determining the drilling parameter further comprises determining the real-time drilling parameter based on the comparison between the actual drilling properties and expected drilling properties; and 
 wherein performing an adjustment of the drilling parameter comprises performing the adjustment of the drilling parameter in real-time. 
 
     
     
       13. The method of  claim 11 , further comprising:
 collecting a second data signal using a second sensor disposed proximate to a second cutter on the drill bit on side of the cutter opposite the sensor, wherein the second cutter is disposed between the sensor and the second sensor; 
 measuring, using the processor and the collected second data signal, a second resistivity profile from the second sensor through the formation; 
 calculating, using the processor, a second distance between the second sensor and the formation using the second resistivity profile; and 
 deriving the actual drilling properties of the wellbore from the second resistivity profile and the second distance. 
 
     
     
       14. The method of  claim 13 ,
 wherein the resistivity profile comprises a plurality of resistivity values from near the sensor and extending through the formation, and 
 wherein the second resistivity profile comprises a second plurality of resistivity values from near the second sensor and extending through the formation. 
 
     
     
       15. The method of  claim 13 , further comprising:
 collecting a third and fourth data signals using a third and fourth sensors disposed on the surface of the drill bit proximate to the cutter along a perpendicular axis that is perpendicular to the direction of bit rotation, wherein the cutter is disposed between the third and fourth sensors; 
 measuring, using the processor and the third and fourth data signals, a third and fourth resistivity profiles from the third and fourth sensors through the formation, respectively; 
 calculating, using the processor, a third and fourth distances between the third and fourth sensors and the formation, respectively, using an inversion scheme, the third and fourth data signals, and the third and fourth resistivity profiles; and 
 generating a two dimensional (2D) visualization using the data signal, the second data signal, and the third and fourth data signals, wherein the 2D visualization represents a contour map of the formation showing a cut surrounding the cutter in the drill bit around where the sensor, the second sensor, and the third and fourth sensors are located.